This course will
introduce students to the entry-level skills necessary in structural analysis
and repair of frame and unibody type vehicles using welding techniques,
measuring equipment and frame machines.
Students will:
1677.1.1 Identify weldable and non-weldable materials
used in autobody components.
1677.1.2 Determine correct electrode wire type,
diameter and gas to be used in specific welding situations.
1677.1.3 Determine the correct type of weld and weld
joint (continuous, stitch/pulse, tack,
plug, etc,) for each specific weld repair.
1677.1.4 Identify safety considerations: eye
protection, proper clothing, shock hazards, dangerous
fumes, etc. before beginning welding operation.
1677.1.5 Set up and tune the welder in accordance
with manufacturers’ instructions; clean the gun and gas nozzle as required.
1677.1.6 Protect computers and other electronic
modules from possible welding damage.
1677.1.7 Clean the metal to be welded; assure good
metal fit through preparation and clamping.
1677.1.8 Use the proper angle of the gun to the
joint, and the direction of gun travel for the type of weld being made in the
flat, horizontal, vertical, and overhead positions.
1677.1.9 Identify cause(s) of splits and sputters,
burn through, lack of penetration, cracks in metal, porosity, incomplete
fusion, excessive spatter, distortion, and waviness of bead; make necessary
adjustments.
1677.1.10 Identify cause(s) of contact tip burn-back
and failure of wire to feed; make necessary adjustments.
Students will:
1677.2.1 Diagnose and measure structural damage using
tram and centering gauges according to manufacturer’s specifications.
1677.2.2 Diagnose and measure unibody damage using a
dedicated (fixture) or universal measuring system compared to specification.
1677.2.3 Attach body anchoring devices.
1677.2.4 Straighten and align all types of frame
damage on a typical frame type vehicle (mash, sag, sideway, twist, kickup,
diamond).
1677.2.5 Straighten and align structural panels on
unibody type vehicles (roof, cowl, pillars, rockers, front and rear sections).
1677.2.6 Apply cold and heat stress relief methods
and weld in accordance with vehicle manufacturer’s recommendations.
1677.2.7 Remove and replace damaged frame horns, side
rails, cross members and structural steel body panels in accordance with
vehicle manufacturers recommendation/industry standards.
1677.2.8 Perform structural panel sectioning in
accordance with vehicle manufacturers specifications/ industry standards.
1677.2.9 Restore corrosion protection to repaired
structural areas in accordance with vehicle manufacturers specifications.
Students will:
1677.3.1 Remove and replace fixed glass (heated and
non-heated) and modular glass using manufacturers procedures.
1677.3.2 Remove and replace butyl-retained and
urethane-retained modular glass with mechanical fasteners.
1677.3.3 Determine when to use the partial cutout or
the full cutout method of repair when replacing a windshield.
